High Voltage Battery Pack R&R

Complete removal and replacement of the high voltage battery pack assembly on a 2024 Rivian EDV 500 electric delivery van, including disconnection of all electrical and cooling system connections.

Warnings

Tools required

Parts

• High voltage battery pack assembly × 1 — Use OEM specification
• Battery coolant quick-connect O-rings × 4 — Use OEM specification
• Battery mounting hardware kit × 1 — Use OEM specification
• High voltage interlock service plug × 1 — Inspect and replace if damaged
• HV connector seals × 2 — Use OEM specification
• Underbody protective covers × 1 — Inspect and replace if damaged

Fluids

• EV Battery/Motor Coolant — 10 qt

Preparation

1. Park vehicle on level surface in well-ventilated area away from ignition sources
2. Ensure vehicle is in PARK mode and power is completely OFF
3. Chock all four wheels securely
4. Connect Rivian diagnostic tool and document all stored fault codes
5. Record high voltage battery serial number, capacity rating, and software version from scan tool
6. Allow vehicle to sit unpowered for minimum 30 minutes to allow capacitors to discharge
7. Put on all required personal protective equipment including high voltage insulated gloves and face shield
8. Place high voltage warning signs around work area
9. Ensure fire extinguisher rated for electrical fires (Class C) is immediately accessible
10. Verify battery lift equipment is in good working order and rated for minimum 1,500 lbs capacity

Procedure

1. 1

   Disable high voltage system using scan tool
   Connect diagnostic scan tool to vehicle OBD port. Navigate to Battery Management System menu. Select 'Service Mode' and initiate 'High Voltage System Shutdown' procedure. Tool will command all high voltage contactors open and disable the system. Wait for confirmation message that system is safe for service. This typically takes 2-3 minutes as the system verifies capacitor discharge.
2. 2

   Remove high voltage service disconnect
   Located under rear cargo area access panel. Remove plastic cover by rotating counterclockwise. Wearing high voltage gloves, grasp orange service disconnect handle and pull straight up with firm, steady pressure to extract. This physically disconnects battery pack from vehicle high voltage system. Store disconnect plug in safe location away from work area. Verify interlock circuit shows open on scan tool.
3. 3

   Verify zero voltage state
   Wait minimum 15 minutes after disconnect removal for capacitor discharge. Using CAT III rated digital multimeter, verify 0V DC between positive and negative HV bus bars at main battery terminals (accessible through service ports on battery pack top). Also verify 0V between each HV terminal and vehicle chassis ground. Document all readings. Do not proceed if any voltage above 5V is detected.
4. 4

   Disconnect 12V auxiliary battery
   Open front hood and locate 12V auxiliary battery. Disconnect negative terminal first, then positive terminal. Secure cables away from battery posts. This prevents any control module activity during battery pack removal and eliminates risk of inadvertent system activation.
5. 5

   Raise vehicle and remove underbody panels
   Lift vehicle on four-post lift to comfortable working height (approximately 4-5 feet). Remove all underbody protective panels covering battery pack area. These include front skid plate, center battery cover panels (typically 3 sections), and rear diffuser panel. Store all fasteners and clips organized by location. Note that center panels have multiple sizes of fasteners.
6. 6

   Drain battery cooling system
   Locate battery coolant drain valve on driver side of battery pack near front edge. Place drain pan underneath with minimum 15 quart capacity. Wearing gloves, slowly open drain valve and allow coolant to drain completely. This takes approximately 15-20 minutes. Once drained, close drain valve. Properly dispose of or recycle old coolant according to local regulations. Label drain pan as this coolant must not be mixed with engine coolant.
7. 7

   Disconnect battery coolant lines
   Locate coolant quick-connect fittings at front of battery pack where coolant lines enter from thermal management system. Press release tabs on both supply and return quick-connects while pulling lines straight out. Have shop towels ready as residual coolant will drain. Cap or plug both battery ports and both lines to prevent contamination. Inspect O-rings in quick-connects and replace if damaged or worn.
8. 8

   Disconnect high voltage power cables
   Wearing high voltage gloves, locate main positive and negative HV cable connections at front of battery pack. Remove orange protective covers. Each connection has a locking collar and bolted connection. Release locking collar first, then remove connection bolts. Carefully separate connectors and immediately install protective covers on both battery terminals and cable ends. Support heavy cables to prevent strain on connections. Mark cables for correct reassembly orientation.
9. 9

   Disconnect battery management system harnesses
   Locate multiple sensor and control harness connectors along both sides of battery pack. These include cell voltage monitoring harnesses (typically 6-8 connectors), temperature sensor harnesses (4 connectors), and main BMS control connector. Disconnect all connectors by releasing locking tabs. Route harnesses away from battery pack and secure to vehicle underbody to prevent damage during removal. Document connector locations with photos for reassembly reference.
10. 10

    Position battery lift equipment
    Carefully position battery lift table or heavy-duty transmission jack under center of battery pack. Use lift assist straps or cradle designed for battery pack removal. Adjust lift height so support equipment makes firm contact with battery pack but does not bear full weight yet. Ensure lift is centered and stable. Battery pack center of gravity is slightly forward of center. Have assistant verify lift positioning from multiple angles before proceeding.
11. 11

    Remove battery pack mounting bolts
    Locate battery pack mounting bolts around perimeter of pack. EDV 500 typically has 16-20 mounting points including main structural bolts (8 locations) and retention brackets. Begin by removing retention bracket bolts, then proceed to main structural mounting bolts. Work in cross-pattern from center outward to maintain even support. Raise lift slightly to take weight as bolts are removed. Keep all mounting hardware organized and inspect threads for damage.
12. 12

    Lower and remove battery pack
    With all mounting hardware removed and assistant present, slowly and carefully lower battery lift. Battery pack weighs approximately 1,400 lbs. Lower in controlled manner, stopping frequently to check clearance of all remaining connections and mounting points. Watch for any snagged wires or coolant lines. Once clear of vehicle, lower completely and carefully roll lift away from vehicle. Place battery on stable, level surface away from work area. Do not stack anything on battery or tilt more than 5 degrees from level.
13. 13

    Inspect mounting points and prepare for installation
    With battery removed, thoroughly inspect all mounting surfaces on vehicle chassis for damage, corrosion, or debris. Clean all mounting surfaces with brake cleaner and wire brush if needed. Inspect all threaded holes and repair any damaged threads. Check condition of all wire harnesses, coolant lines, and HV cables for wear or damage. Replace any damaged components before installing new battery. Apply light coat of anti-seize to mounting bolt threads unless thread-locking compound will be used.
14. 14

    Install replacement battery pack
    Position new battery pack on lift equipment ensuring proper orientation (front/rear and left/right positioning). Verify battery serial number matches order documentation. Carefully raise battery into position under vehicle, guiding through chassis opening. Align mounting points carefully, using assistant to verify alignment from multiple angles. Raise until battery contacts mounting surfaces but do not fully seat yet. Verify no harnesses or lines are pinched.
15. 15

    Install and torque mounting hardware
    Install all battery pack mounting bolts hand-tight first, starting with main structural bolts. Ensure all mating surfaces are properly aligned. Once all bolts are started, torque in cross-pattern from center outward. Since no torque specifications are provided in database, follow values marked on new battery pack documentation or Rivian service manual. Apply medium-strength thread locking compound to specified bolts per service manual. Double-check all fasteners are secure. Remove battery lift equipment only after all mounting bolts are fully torqued.

Reassembly

1. Reconnect all battery management system harnesses to correct locations using photos taken during disassembly
2. Install new O-rings on coolant quick-connect fittings and reconnect supply and return lines with firm push until click is heard
3. Remove protective covers and reconnect high voltage power cables ensuring correct polarity, torque per specifications, and install locking collars and orange protective covers
4. Refill battery cooling system through fill port with fresh EV Battery/Motor Coolant to specified level, then bleed air from system using scan tool coolant bleeding procedure
5. Reconnect 12V auxiliary battery starting with positive terminal, then negative terminal
6. Reinstall all underbody protective panels and skid plates with all fasteners in correct locations
7. Lower vehicle to ground

Verification

• With high voltage service disconnect still removed, reconnect 12V battery and connect scan tool
• Check for any new fault codes related to battery installation or harness connections
• Verify battery serial number is correctly recognized by vehicle systems through scan tool
• Perform battery management system initialization procedure using scan tool per Rivian service procedures
• Verify coolant system shows no leaks and proper circulation when thermal management system activates
• Install high voltage service disconnect plug, rotating clockwise until fully seated and locked
• Using scan tool, exit service mode and enable high voltage system
• Verify high voltage system activates properly and battery voltage displays correctly on scan tool (should show pack voltage around 400-800V depending on state of charge)
• Perform high voltage insulation resistance test using scan tool to verify no isolation faults (resistance should exceed 500 ohms/volt)
• Clear any stored fault codes that are installation-related and verify no permanent codes remain
• Power on vehicle and verify READY mode can be achieved and all battery-related warnings are cleared from instrument cluster
• Perform test drive monitoring battery performance, power delivery, and regenerative braking function
• After test drive, re-check all connections and verify no coolant leaks are present
• Document final battery state of charge, system voltage, and any relevant parameters in service records

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